Boxed plate construction frame with integral engine support section

ABSTRACT

A chassis frame includes a side rails and cross-members that intersect at a number of intersection points, which collectively define a chassis frame with front and rear portions that define a main support section and an integral engine support section. Each side rail includes a top plate, a bottom plate, and first and second side plates extending between the top and bottom plates. The first and second side plates each have a first end coupled to a bottom surface of the top plate and a second end coupled to the top surface of the bottom plate. Each cross-member includes a top plate, a bottom plate, and first and second side plates extending between the top plate and bottom plates. The first and second side plates each have a first end coupled to a bottom surface of the top plate and a second end coupled to the top surface of the bottom plate. A plurality of gusset portions is formed between the top plates of the side rails and cross-members at each intersection point.

FIELD OF THE INVENTION

The invention relates generally to agricultural product application equipment such as self-propelled sprayers and, in particular, to a boxed plate construction frame including numerous plate segments welded together to provide an integral engine supporting section, frame slider receivers, component and accessory mounting structures, and boxed side rails and cross members.

BACKGROUND OF THE INVENTION

High-clearance spreaders are getting larger and heavier over time to allow for carrying longer booms that provide increased coverage in a single pass. High-clearance sprayers are also getting more complex, with accessories that improve machine efficiency and user comfort. These large high-clearance sprayers require larger and stronger frames to support the sprayer itself and its various accessories.

In order to provide sufficient strength and mounting locations for components and accessory-supporting brackets, high-clearance sprayer frames are currently made in a ladder-style configuration made from numerous large sections of tubing to which various open channels, plates, and/or other webs of materials may be attached, such as in a vertical stack that adds to the overall height of the frame. These ladder-style tube frames can be relatively heavy and have numerous individual components that can require substantial amounts of time for fit-up and welding while fabricating. Even more time can be needed for some frames that are constructed as multiple individual frame sections, such as a main frame section and an engine supporting sub-frame section, that are later connected to each other during final assembly.

The boxed plate frame of the invention is made without interconnected tube or channels stacked on tubes. Instead, it is made from plate segments that are cut out from plate material and welded together to make a fully boxed frame. As a result, the boxed plate constructed frame of the current invention is wider, shorter, and lighter than the current ladder-style tube frame while simultaneously constructing the engine supporting section with the rest of the frame, instead of creating a separate weldment or sub-frame for an engine support that has to be separately attached to the chassis frame.

SUMMARY OF THE INVENTION

The present invention is directed to a boxed plate construction frame with an integral engine support section. The boxed plate construction frame may have plates of varying thicknesses based on the strength needs at the respective different portions of the chassis frame. The boxed plate constructed frame provides thicker material only where extra strength is needed.

According to one aspect of the invention, a chassis frame includes a plurality of side rails and a plurality of cross-members that intersect at a plurality of intersection points. Each side rail includes a top plate, a bottom plate spaced apart from the top plate, a first side plate extending from the top plate to the bottom plate, and a second side plate extending from the top plate to the bottom plate. Each of the first and second side plates has a first end coupled to a bottom surface of the top plate and a second end coupled to the top surface of the bottom plate. Similarly, each cross-member includes a top plate, a bottom plate spaced apart from the top plate, a first side plate extending from the top plate to the bottom plate, and a second side plate extending from the top plate to the bottom plate. Each of the first and second side plates has a first end coupled to a bottom surface of the top plate and a second end coupled to the top surface of the bottom plate. The chassis frame further includes a plurality gusset portions formed between the top plate of the side rails and the top plate of the cross-members at each intersection point.

In accordance with another aspect of the invention, the first side plate of each side rail is welded to the top plate of its respective side rail at a location between a first end of the top plate and a center of the top plate. Likewise, the second side plate of each side rail is welded to the top plate of its respective side rail at a location between a second end of the top plate and the center of the top plate.

In accordance with yet another aspect of the invention, the first side plate of each cross-member is welded to the top plate of its respective cross-member at a location between a first end of the top plate and a center of the top plate. Similarly, the second side plate of each cross-member is welded to the top plate of its respective cross-member at a location between a second end of the top plate and the center of the top plate.

In accordance with another aspect of the invention, the chassis frame also includes at least one central opening between the intersecting side rails and cross-members. Each intersection point forms one of a plurality of corners of a respective central opening. In some embodiments of the invention, each corner of a respective central opening has a curved shape that follows the curved inner perimeter of a respective gusset portion.

In accordance with yet another aspect of the invention, each side rail and cross-member respectively, includes a hollow cavity surrounded by the top plate, bottom plate, first side plate, and second side plate.

According to another aspect of the invention, a method of manufacturing a chassis frame includes forming a plurality of side rails, forming a plurality of cross-members, and intersecting each cross-member with the plurality of side rails at a plurality of intersection points. Forming each side rail includes providing a top plate, providing a bottom plate spaced apart from the top plate, welding a first end of a first side plate to a bottom surface of the top plate, welding a second end of the first side plate to a top surface of the bottom plate, welding a first end of a second side plate to the bottom surface of the top plate, and welding a second end of the second side plate to the top surface of the bottom plate. Forming each cross-member includes providing a top plate, providing a bottom plate spaced apart from the top plate, welding a first end of a first side plate to a bottom surface of the top plate, welding a second end of the first side plate to a top surface of the bottom plate, welding a first end of a second side plate to the bottom surface of the top plate, and welding a second end of the second side plate to the top surface of the bottom plate. The method further includes providing gusset portions at each intersection point to extend between the top plate of one of the plurality of side rails and the top plate of a respective one of the plurality of cross-members.

In accordance with another aspect of the invention, welding a first end of a first side plate to a bottom surface of the top plate includes welding the first end of the first side plate to the bottom surface of the top plate at a location between a first end of the top plate and a center of the top plate. Similarly, welding a first end of the second side plate to the bottom surface of the top plate includes welding the first end of the second side plate to the bottom surface of the top plate at a location between a second end of the top plate and the center of the top plate. In addition, welding a second end of a first side plate to a top surface of the bottom plate includes welding the second end of the first side plate to the top surface of the bottom plate at a location between a first end of the bottom plate and a center of the bottom plate. Likewise, welding a second end of the second side plate to the top surface of the top plate includes welding the second end of the second side plate to the bottom surface of the bottom plate at a location between a second end of the bottom plate and the center of the bottom plate.

In accordance with yet another aspect of the invention, the method includes forming at least one central opening having a perimeter surrounded by intersecting side rails and cross-members. Further, each corner of each central opening may have a curve matching the inner perimeter of a respective gusset portion.

In accordance with another aspect of the invention, forming each side rail includes surrounding a hollow cavity with the top plate, bottom plate, first side plate, and second side plate. Similarly, forming each cross-member includes surrounding a hollow cavity with the top plate, bottom plate, first side plate, and second side plate.

According to yet another aspect of the invention, a chassis frame includes two side rails oriented parallel to each other and a plurality of cross-members oriented perpendicular to the side rails and extending therebetween. Each side rail includes a top plate, a bottom plate spaced apart from and oriented parallel to the top plate, an inner wall plate extending from a bottom surface of the top plate to the top surface of the bottom plate, and an outer wall plate extending from the bottom surface top plate to the top surface of the bottom plate. Each cross-member includes a top plate, a bottom plate spaced apart from and oriented parallel to the top plate, a front wall plate extending from a bottom surface of the top plate to the top surface of the bottom plate, and a rear wall plate extending from the bottom surface of the top plate to the top surface of the bottom plate. Further, each cross-member extends from a respective side rail at a respective one of a plurality of intersection points and gusset portions are formed between the top plate of the side rails and the top plate of the cross-members at each intersection point.

In accordance with another aspect of the invention, a portion of the top plate of each side rail adjacent an inner edge of the top plate extends beyond the inner wall plate of the side rail. Similarly, a portion of the top plate of each cross-member adjacent a front edge of the top plate extends beyond the front wall plate of the cross-member, and a portion of the top plate of each cross-member adjacent a rear edge of the top plate extends beyond the rear wall plate of the cross-member.

In accordance with yet another aspect of the invention, the chassis frame includes at least one central opening having a perimeter surrounded by intersecting side rails and cross-members.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred exemplary embodiments of the invention are illustrated in the accompanying drawings in which like reference numerals represent like parts throughout.

FIG. 1 is an isometric view of an agricultural machine;

FIG. 2 is a perspective view of a chassis frame of the agricultural machine;

FIG. 3 is a top view of the chassis frame of FIG. 2;

FIG. 4 is a cross-sectional view of a cross-member from a front portion of the chassis frame of FIG. 3, taken along line 4-4;

FIG. 5 is a cross-sectional view of a cross-member from a rear portion of the chassis frame of FIG. 3, taken along line 5-5;

FIG. 6 is a cross-sectional view of a side rail from the front portion of the chassis frame of FIG. 3, taken along line 6-6;

FIG. 7 is a cross-sectional view of a side rail from the rear portion of the chassis frame of FIG. 3, taken along line 7-7;

FIG. 8 is an enlarged view of section 9-9 of a transition joint the chassis frame of FIG. 3; and

FIG. 9 is a cross-sectional view of the transition joints of the chassis frame of FIG. 3 taken along line 9-9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

Referring now to the drawings and specifically to FIG. 1, aspects of the invention are shown for use with an agricultural machine, for example, but not limited to, an agricultural sprayer. The agricultural sprayer is shown here as a self-propelled agricultural sprayer vehicle or self-propelled sprayer 10. Although the sprayer 10 is shown as a front-mounted boom self-propelled sprayer, it is understood that self-propelled versions of the sprayer 10 can have either front-mounted or rear-mounted booms, such as those available from CNH Industrial, including the Miller Nitro and Condor Series sprayers, and New Holland Guardian Series sprayers.

Still referring to FIG. 1, the sprayer 10 includes a chassis 12 having a chassis frame 14 that supports various assemblies, systems, and components. These various assemblies, systems, and components can include an operator cab 16, an engine 18, an engine accessory system 34, and a hydraulic system 20. The hydraulic system 20 receives power from the engine 18 and includes at least one hydraulic pump which can be in a hydrostat arrangement for providing hydraulic pressure for operating hydraulic components within the hydraulic system 20. For sprayers with hydrostatic drives, hydraulic motors are operably connected to the hydraulic pump(s) for rotating the wheels 22. In mechanical drive applications, a mechanical transmission receives power from the engine 18 and delivers power for rotating the wheels 22 by way of power-transmitting driveline components such as drive shafts, differentials, and other gear sets in portal, drop boxes, or other housings. A spray system 24 can include storage containers such as a rinse tank 26 for storing water or a rinsing solution and a product tank 28 for storing a volume of product for delivery onto an agricultural field with the sprayer 10. A product delivery pump can convey product from the product tank 28 through plumbing components such as interconnected pieces of tubing and through a boom tubing system for release out of spray nozzles that are spaced from each other along the width of boom 30 during spraying operations of the sprayer 10. Groups or banks of multiple adjacent spray nozzles define multiple spray sections of the spray system. Spray sections are defined along the boom 30 and selectively deliver product for release onto an agricultural field at locations corresponding to positions of activated spray sections. The boom 30 is connected to the chassis 12 with the lift arm assembly 32 that is configured to move the boom 30 up and down for adjusting the height of application of the product.

FIGS. 2 and 3 depict perspective and top views, respectively, of the chassis frame 14 of the sprayer 10 without the operator cab 16, engine 18, hydraulic system 20, spray system 24, rinse tank 26, product tank 28, boom 30, lift arm assembly 32, and engine accessory system 34 removed, in order to further illustrate the chassis frame 14. As will be described in further detail below, the chassis frame 14 is a boxed plate constructed frame having top and bottom walls 36, 38, respectively. The top and bottom walls 36, 38 of the chassis frame 14 may be one of a number of thicknesses depending the strength needs of a specific section of the chassis frame 14.

The chassis frame 14 includes a front portion 14 a, which is situated under and supports the weight of the operator cab 16, lift arm assembly 32, boom 30, rinse tank 26, product tank 28, and spray system 34 so that the front portion 14 a defines a main support section of chassis frame 14. The chassis frame 14 further also includes a rear portion 14 b, which is situated under and supports the weight of the engine 18 and engine accessory system 34 so that the rear portion 14 b defines an engine support section of the chassis frame 14. The front and rear portions 14 a, 14 b of the chassis frame 14 are joined together at a plurality of transition joints 40, which will be described later in further detail.

The chassis frame 14 includes two (2) side rails 42 that run along the length of the chassis frame 14. As shown in FIGS. 2 and 3, the side rails 42 are oriented parallel to each other. While the representative embodiment of the invention illustrates the use of two (2) side rails 42, it is contemplated that other embodiments of the invention may use more or less than two (2) side rails 42.

The chassis frame 14 further includes a plurality of cross-members 44 that extend between the side rails 42 and are oriented perpendicular thereto. As show in FIGS. 2 and 3, the each cross-member 44 intersects with a side rail 42 at an intersection point 46. In varying embodiments of the invention, each cross-member 44 intersects with at least two (2) side rails 42 at respective intersection points 46. While the representative embodiment of the invention illustrates the top walls 36 of the chassis frame as being integral across adjacent side rails 42 and cross-members 44, it is also contemplated that each side rail 42 and cross-member 44 may distinct top walls 36 that re coupled together. It is contemplated that any number of cross-members 44 may be used in varying embodiments of the invention. In addition, while the representative embodiment of the invention depicts each cross-member 44 extending between respective side rails 42 and terminating at each intersection point 46, alternative embodiments of the invention may include cross-members 44 that extend beyond the intersection points 46 and the side rails 42.

The chassis frame 14 may also include a plurality of openings 48 throughout the chassis frame 14, which result in reduced weight. As shown in FIGS. 2 and 3, the intersection of side rails 42 and cross-members 44 results in openings surrounded by adjacent side rails 42 and cross-members 44, between the intersecting side rails and cross-members 44. Each intersection point 46 is associated with a corner 50 of at least one central opening 48. The perimeter 52 of each central opening 48 is defined by the edges of the adjacent side rails 42 and cross-members 44.

The top wall 36 of the chassis frame 14 may also include gusset portions 54. Each gusset portion 54 is located at a respective corner 50 of a central opening 48. As a result of the gusset portions 54, the corners or the central opening 48 are rounded in shape. In addition, the gusset portions 54 reduced force concentrations at the transition joints 40 between the side rails 42 and the cross-members 44. That is, the gusset portions 54 provide a greater surface area at each intersection joint 40 to spread the forces across a greater surface area.

The term permanently coupled, as used below and throughout the application, may refer to, but is not limited, a welded connection between elements.

Next, FIG. 4 illustrates a cross-sectional view of a cross-member 44 a from the front portion 14 a of the chassis frame 14 of FIG. 3, taken along line 4-4. As shown in the cross-sectional view of FIG. 4, the cross-member 44 a of the chassis frame 14 is formed by a top plate 56 a, a bottom plate 58 a, a front side plate 60 a, and a rear side plate 62 a, which surround a hollow cavity 64 a. The hollow cavity 64 a of the cross-member 44 a assists in reducing the weight of the chassis frame 14.

The front side plate 60 a includes a first end 66 a and a second end 68 a. The first end 66 a of the front side plate 60 a is permanently coupled to a bottom surface 70 a of the top plate 56 a at a first location 72 a between a first end 74 a and a center point 76 a of the top plate 56 a. The second end 68 a of the front side plate 60 a is permanently coupled to a top surface 78 a of the bottom plate 58 a at a first location 80 a between a first end 82 a and a center point 84 a of the bottom plate 58 a. Similarly, the rear side plate 62 a includes a first end 86 a and a second end 88 a. The first end 86 a of the rear side plate 62 a is permanently coupled to the bottom surface 70 a of the top plate 56 a at a second location 90 a between a second end 92 a and the center point 76 a of the top plate 56 a. The second end 88 a of the rear plate 62 a is permanently coupled to the top surface 78 a of the bottom plate 58 a at a second location 94 a between a second end 96 a and the center point 84 a of the bottom plate 58 a.

In light of the construction above, the top plate 56 a includes a portion 100 a adjacent the first end 74 a of the top plate 56 a that extends beyond the front side plate 60 a. The top plate 56 a also includes another portion 102 a adjacent the second end 92 a of the top plate 56 a that extends beyond the rear side plate 62 a. Similarly, the bottom plate 58 a includes a portion 104 a, which is adjacent the first end 82 a of the bottom plate 58 a and extends beyond the front side plate 60 a, and a portion 106 a, which is adjacent the second end 96 a of the bottom plate 58 a and extends beyond the rear side plate 62 a.

In alternative embodiments of the invention, the front and rear side plates 60 a, 62 a may between the ends 74 a, 92 a, 82 a, 96 a, of the top and bottom plates 56 a, 58 a, respectively. In such alternative embodiments of the invention, the top and bottom plates 56 a, 58 a would not include portions 100 a, 102 a, 104 a, 106 a, respectively.

Now referring to FIG. 5, a cross-sectional view of a cross-member 44 b from the rear portion 14 b of the chassis frame 14 of FIG. 3, taken along line 5-5, is shown. Similar to the cross-members 44 a, the cross-members 44 b include a top plate 56 b, a bottom plate 58 b, a front side plate 60 b, and a rear side plate 62 b, which surround a hollow cavity 64 b. As with the hollow cavity 64 a, the hollow cavity 64 b assists in reducing the weight of the chassis frame 14.

As discussed above, the construction of cross-member 44 b is similar to the construction of cross-member 44 a. The front side plate 60 b includes a first end 66 b and a second end 68 b. The first end 66 b of the front side plate 60 b is permanently coupled to a bottom surface 70 b of the top plate 56 b at a first location 72 b between a first end 74 b and a center point 76 b of the top plate 56 b. The second end 68 b of the front side plate 60 b is permanently coupled to a top surface 78 b of the bottom plate 58 b at a first location 80 b between a first end 82 b and a center point 84 b of the bottom plate 58 b. Similarly, the rear side plate 62 b includes a first end 86 b and a second end 88 b. The first end 86 b of the rear side plate 62 b is permanently coupled to the bottom surface 70 b of the top plate 56 b at a second location 90 b between a second end 92 b and the center point 76 b of the top plate 56 b. The second end 88 b of the rear plate 62 b is permanently coupled to the top surface 78 b of the bottom plate 58 b at a second location 94 b between a second end 96 b and the center point 84 b of the bottom plate 58 b.

In the representative embodiment of the invention, the top plate 56 b includes a portion 100 b adjacent the first end 74 b of the top plate 56 b, which extends beyond the front side plate 60 b, and another portion 102 b adjacent the second end 92 b of the top plate 56 b, which extends beyond the rear side plate 62 b. Likewise, the bottom plate 58 b includes a portion 104 b adjacent the first end 82 b of the bottom plate 58 b, which extends beyond the front side plate 60 b, and a portion 106 b adjacent the second end 96 b of the bottom plate 58 b, which extends beyond the rear side plate 62 b.

As described above with respect to cross-member 44 a, the front and rear side plates 60 b, 62 b of cross-member 44 b extend between the ends 74 b, 92 b, 82 b, 96 b of the top and bottom plates 56 b, 58 b, respectively. In these alternative embodiments of the invention, the top and bottom plates 56 b, 58 b would not include portions 100 b, 102 b, 104 b, 106 b, respectively.

In the representative embodiments of the invention shown in FIGS. 4 and 5, the top plate 56 and the bottom plate 58 are spaced apart from each other and oriented parallel or substantially parallel to each other. In addition, the front and rear side plates 60, 62 extend perpendicularly or substantially perpendicularly between the top and bottom plates 56, 58, as described above.

A thickness of the top plate 56 a may differ than the thickness of the top plate 56 b, based on the strength needs at the respective portions 14 a, 14 b of the chassis frame 14. A thickness of the bottom plates 58 a, 58 b may also differ to provide additional strength in areas of need. In one embodiment of the invention, the thickness of the top and bottom plates 56 a, 58 a may be greater than the thickness of the top and bottom plates 56 b, 58 b, in order to provide the additional strength necessary to support the boom 30 and other components at the front portion 14 a of the chassis frame 14. In the representative embodiment of the invention, the thickness of the top and bottom plates 56 a, 58 a may be 0.25 inch (¼ inch), while the thickness of the top and bottom plates 56 b, 58 b may be 0.1875 inch ( 3/16 inch). However, it is also contemplated that the top and bottom plates 56 b, 58 b may have greater thicknesses that that of top and bottom plates 56 a, 58 a in other embodiments of the invention.

In alternative embodiments of the invention, the thickness of the top plates 56 a, 56 b may be adjusted by the inclusion of additional plates. For instance, the top plates 56 a, 56 b may each include a number of plates welded together to provide the necessary thicknesses and strength, respectively. As such, the thickness of the top plates 56 a, 56 b may be adjusted at specific locations requiring extra strength across the chassis frame 14. While, in one instance, the top plate 56 a may include a greater number of plates than the top plate 56 b to provide a greater thickness and strength, it is also contemplated that the top plate 56 b may include a greater number of plates than the top plate 56 a, in other embodiments of the invention.

Next, FIG. 6 depicts a cross-sectional view of a side rail 42 a from the front portion 14 a of the chassis frame 14 of FIG. 3, taken along line 6-6. The cross-sectional view of the side rail 42 a is similar in construction to the previously described cross-members 44 a, 44 b. The side rail 42 a includes a top plate 106 a spaced apart from and oriented parallel or substantially parallel to a bottom plate 108 a, a first, inner side plate 110 a extending between and oriented perpendicular or substantially perpendicular to the top and bottom plates 106 a, 108 a, and a second, outer side plate 112 a extending between and oriented perpendicular or substantially perpendicular to the top and bottom plates 106 a, 108 a. The plates 106 a, 108 a, 110 a, 112 a surround a hollow cavity 114 a within the side rail 42 a, which assists in reducing the weight of the chassis frame 14.

As shown in FIG. 6, the top plate 106 a and the bottom plate 108 a each include a first end 116 a, 118 a and a second end 120 a, 122 a, respectively. The inner side plate 110 a includes a first end 124 a permanently coupled to a bottom surface 126 a of the top plate 106 a at a location 128 a between the first end 116 a and a center point 130 a of the top plate 106 a. The inner side plate 110 a also includes a second end 132 a permanently coupled to a top surface 134 a of the bottom plate 108 a at a location 136 a between the first end 118 a and a center point 138 a of the bottom plate 108 a. Similarly, the outer side plate 112 a includes a first end 140 a permanently coupled to the bottom surface 126 a of the top plate 106 a at a location 142 a between the second end 120 a and the center portion 130 a of the top plate 106 a. The outer side plate 112 a also includes a second end 144 a permanently coupled to the top surface 134 a of the bottom plate 108 a at a location 146 a between the second end 122 a and the center point 138 a of the bottom plate 108 a.

In the representative embodiment of the invention, the top plate 106 a includes a portion 148 a adjacent the first end 116 a of the top plate 106 a that extends beyond the inner side plate 110 a. The top plate 106 a include another portion 150 a adjacent the second end 120 a of the top plate 106 a that extends beyond the outer side plate 112 a. Likewise, the bottom plate 108 a includes a portion 152 a adjacent the first end 118 a of the bottom plate 108 a, which extends beyond the inner side plate 110 a, and a portion 154 a adjacent the second end 122 a of the bottom plate 108 a, which extends beyond the outer side plate 112 a.

In other embodiments of the invention, the inner and outer side plates 110 a, 112 a may extend between the top and bottom plates 106 a, 108 a at their respective ends 116 a, 120 a, 118 a, 122 a. In such an embodiment of the invention, the top and bottom plates 106 a, 108 a would not include portions 148 a, 150 a, 152 a, 154 a, respectively.

Now referring to FIG. 7, a cross-sectional view of a side rail 44 b from the rear portion 14 b of the chassis frame 14 is shown, taken along line 7-7 of FIG. 3. The construction of side rail 44 b is similar to the construction of side rail 44 a, described above with respect to FIG. 6. The side rail 42 b includes a top plate 106 b spaced apart from and oriented parallel or substantially parallel to a bottom plate 108 b, an inner side plate 110 b that extends between and is oriented perpendicular or substantially perpendicular to the top and bottom plates 106 b, 108 b, and an outer side plate 112 b that extends between and is oriented perpendicular or substantially perpendicular to the top and bottom plates 106 b, 108 b. The plates 106 b, 108 b, 110 b, 112 b surround a hollow cavity 114 b within the side rail 42 b. The hollow cavity 114 b assists in reducing the weight of the chassis frame 14.

In the representative embodiment of the invention, the inner side plate 110 b includes a first end 124 b permanently coupled to a bottom surface 126 b of the top plate 106 b at a location 128 b between a first end 116 b and a center point 130 b of the top plate 106 b. The inner side plate 110 b further includes a second end 132 b permanently coupled to a top surface 134 b of the bottom plate 108 b at a location 136 b between a first end 118 b and a center point 138 b of the bottom plate 108 b. Meanwhile, the outer side plate 112 b includes a first end 140 b permanently coupled to the bottom surface 126 b of the top plate 106 b at a location 142 b between a second end 120 b and the center portion 130 b of the top plate 106 b. The outer side plate 112 b further includes a second end 144 b permanently coupled to the top surface 134 b of the bottom plate 108 b at a location 146 b between a second end 122 b and the center point 138 b of the bottom plate 108 b.

FIG. 7 further illustrates the top plate 106 b including a portion 148 b adjacent the first end 116 b of the top plate 106 b, which extends beyond the inner side plate 110 b, and another portion 150 b adjacent the second end 120 b of the top plate 106 b, which extends beyond the outer side plate 112 b. Similarly, the bottom plate 108 b includes a portion 152 b adjacent the first end 118 b of the bottom plate 108 b, which extends beyond the inner side plate 110 b, and another portion 154 b adjacent the second end 122 b of the bottom plate 108 b, which extends beyond the outer side plate 112 b.

In alternative embodiments of the invention, the inner and outer side plates 110 b, 112 b may extend between the top and bottom plates 106 b, 108 b from their ends 116 b, 120 b, 118 b, 122 b, respectively. In these embodiment of the invention, the top and bottom plates 106 b, 108 b would not include respective portions 148 b, 150 b, 152 b, 154 b.

A thickness of the top plate 106 a may differ than the thickness of the top plate 106 b, based on the strength needs at the respective portions 14 a, 14 b of the chassis frame 14. In addition, a thickness of the bottom plates 108 a, 108 b may differ to provide even more strength in areas of need. In one embodiment of the invention, the thickness of the top and bottom plates 106 a, 108 a may be greater than the thickness of the top and bottom plates 106 b, 108 b, in order to provide the additional strength necessary to support the boom 30 and other components at the front portion 14 a of the chassis frame 14. In the representative embodiment of the invention, the thickness of the top and bottom plates 106 a, 108 a may be 0.25 inch (¼ inch), while the thickness of the top and bottom plates 106 b, 108 b may be 0.1875 inch ( 3/16 inch). However, it is also contemplated that the top and bottom plates 106 b, 108 b may have greater thicknesses than that of top and bottom plates 106 a, 108 a in other embodiments of the invention. That is, different configurations of components of the sprayer 10 on the chassis frame 14 may result in different strength needs of the chassis frame 14.

In yet other embodiments of the invention, the thickness of the top plates 106 a, 106 b may be adjusted by adjusting the number of plates welded together to create the top plate 106 a, 106 b. For example, the top plates 106 a, 106 b may each include a number of plates welded together to provide the necessary thicknesses and strength, respectively. As such, the thickness of the top plates 106 a, 106 b may be adjusted at specific locations that require extra strength across the chassis frame 14. In one instance, the top plate 106 a may include a greater number of plates than the top plate 106 b to provide a greater thickness and strength, while, in other instances, the top plate 106 b may include a greater number of plates than the top plate 106 a, in other embodiments of the invention.

Next, FIG. 8 depicts an enlarged view of the transition joint 40 of the chassis frame 14. The transition joint 40 is formed by the merging of a pocket 156 and a protrusion 158. The pocket 156 is formed adjacent each side rail 42 b of the rear portion 14 b of the chassis frame 14 at an end 160 of the rear portion 14 b adjacent the front portion 14 a of the chassis frame 14. The protrusion 158 is formed adjacent each side rail 42 a of the front portion 14 a of the chassis frame 14 at an end 162 of the front portion 14 a adjacent the rear portion 14 b of the chassis frame 14.

Adjacent the side rails 42 b, each corner 164 of the rear portion 14 b of the chassis frame 14 at the end 160 of the rear portion 14 b of the chassis frame 14 includes a plurality of angular edges 166. In the representative embodiment of the invention, three (3) angular edges 166 form each pocket 156. In alternative embodiments of the invention, any number of angular edges 166 may be used to form each pocket 156. As shown in FIG. 8, the angular edges 166 adjust the profile of the top and bottom walls 36 b, 38 b of the rear portion 14 b of the chassis frame 14.

Adjacent the side rails 42 a, each corner 168 of the front portion 14 a of the chassis frame 14 includes a plurality of angular edges 170 forming each protrusion 158. In the representative embodiment of the invention, three (3) angular edges 170 form each protrusion 158. However, any number of angular edges 170 may be used to form each protrusion 158. Similar to the angular edges 166 of the rear portion 14 b of the chassis frame 14, the angular edges 170 of the front portion 14 b of the chassis frame 14 adjust the profile of the top and bottom walls 36 a, 38 a of the front portion 14 a of the chassis frame 14.

FIG. 9 depicts a cross-sectional view of the transition joint 40. As shown in the representative embodiment of the invention, the front and rear portions 14 a, 14 b of the chassis frame 14 are aligned at the transition joints 40 so that angular edges 166, 170 align with each other. In addition, the front and rear portions 14 a, 14 b are aligned so that the bottom surfaces 70 of the top plates 56 and the bottom surfaces 126 of the top plates 106 are aligned along the same horizontal plane. Similarly, the front and rear portions 14 a, 14 b are aligned so that the top surfaces 78 of the bottom plates 58 and the top surfaces 134 of the bottom plates 108 are aligned along the same horizontal plane.

As the angular edges 166, 170 are aligned and brought together so that the pocket 156 and protrusion 158 may engage each other, an upper seam 172 is created in the top wall 36 and a lower seam 174 is created in the bottom wall 38 where the angular edges 166 come together. As shown in FIG. 9, the angular edges 166, 170 may be flush against each other or spaced apart from each other along the seams 172, 174. Further, whether the angular edges 166, 170 are flush against each other or spaced apart from each may vary across the length of the seams 172, 174.

In the representative embodiment of the invention, an upper joining plate 176 is disposed on the bottom surface 180 of the top wall 36 of the chassis frame 14 along the upper seam 172. The upper joining plate 176 may be disposed along the entirety of the upper seam 172 or only a portion of the upper seam 172. Similarly, a lower joining plate 178 may be disposed on the top surface 182 of the bottom wall 38 of the chassis frame 14 along the lower seam 174. The lower joining plate 178 may also be disposed along the entirety of the lower seam 174 or only a portion of the lower seam 174.

Although the best mode contemplated by the inventors of carrying out the present invention is disclosed above, practice of the above invention is not limited thereto. It will be manifest that various additions, modifications and rearrangements of the features of the present invention may be made without deviating from the spirit and the scope of the underlying inventive concept. 

We claim:
 1. A chassis frame of an agricultural sprayer comprising: a main support section configured to support at least one of an operator cab and a product tank; an engine support section configured to support an engine and wherein the main support section and the engine support section are collectively defined by: a plurality of side rails, each side rail comprising: a top plate; a bottom plate spaced apart from the top plate; a first side plate extending from the top plate to the bottom plate; a second side plate extending from the top plate to the bottom plate; and wherein each of the first and second side plates has a first end coupled to a bottom surface of the top plate and a second end coupled to the top surface of the bottom plate; a plurality of cross-members, each cross-member comprising: a top plate; a bottom plate spaced apart from the top plate; a first side plate extending from the top plate to the bottom plate; a second side plate extending from the top plate to the bottom plate; and wherein each of the first and second side plates has a first end coupled to a bottom surface of the top plate and a second end coupled to the top surface of the bottom plate; a top wall extending over the top plate of at least one of the plurality of cross-members and over the top plate of at least one of the plurality of side rails; and wherein: the plurality of side rails and the plurality of cross-members intersect at a plurality of intersection points; a plurality of gusset portions is formed between the top plate of the side rails and the top plate of the cross-members at each intersection point; wherein: the top plate of one of the plurality of cross-members includes a first section having multiple angled edges defining a pocket therein and a second section having multiple angled edges defining a protrusion; the protrusion is receivable in the pocket so as to define a transition joint between the first and second sections of the one of the plurality of cross-members.
 2. The chassis frame of claim 1 wherein the first side plate of each side rail is welded to the top plate of its respective side rail at a location between a first end of the top plate and a center of the top plate; and wherein the second side plate of each side rail is welded to the top plate of its respective side rail at a location between a second end of the top plate and the center of the top plate.
 3. The chassis frame of claim 1 wherein the first side plate of each cross-member is welded to the top plate of its respective cross-member at a location between a first end of the top plate and a center of the top plate; and wherein the second side plate of each cross-member is welded to the top plate of its respective cross-member at a location between a second end of the top plate and the center of the top plate.
 4. The chassis frame of claim 1 further comprising at least one central opening disposed between the intersecting side rails and cross-members; and wherein each intersection point forms one of a plurality of corners of a respective central opening.
 5. The chassis frame of claim 4 wherein each corner of a respective central opening has a curved shape that follows a curved inner perimeter of a respective gusset portion.
 6. The chassis frame of claim 1 wherein each side rail has a hollow cavity surrounded by the top plate, bottom plate, first side plate, and second side plate; and wherein each cross-member has a hollow cavity surrounded by the top plate, bottom plate, first side plate, and second side plate.
 7. The chassis frame of claim 1 wherein the plurality of side rails and the plurality of cross-members intersect perpendicularly.
 8. A method of manufacturing a chassis frame comprising: forming a main frame section for supporting at least one of an operator cab and a product tank and an engine support section configured to support an engine by: forming a plurality of side rails, wherein forming each side rail comprises: providing a top plate; providing a bottom plate spaced apart from the top plate; welding a first end of a first side plate to a bottom surface of the top plate; welding a second end of the first side plate to a top surface of the bottom plate; welding a first end of a second side plate to the bottom surface of the top plate; and welding a second end of the second side plate to the top surface of the bottom plate; forming a plurality of cross-members, wherein forming each cross-member comprises: providing a top plate; providing a bottom plate spaced apart from the top plate; welding a first end of a first side plate to a bottom surface of the top plate; welding a second end of the first side plate to a top surface of the bottom plate; welding a first end of a second side plate to the bottom surface of the top plate; and welding a second end of the second side plate to the top surface of the bottom plate; intersecting each cross-member with the plurality of side rails at a plurality of intersection points; and extending a top wall over the top plate of at least one of the plurality of cross-members and over the top plate of at least one of the plurality of side rails; and providing gusset portions at each intersection point to extend between the top plate of one of the plurality of side rails and the top plate of a respective one of the plurality of cross-members; and wherein: the top plate of one of the plurality of cross-members includes a first section having multiple angled edges defining a pocket therein and a second section having multiple angled edges defining a protrusion; and the protrusion is receivable in the pocket so as to define a transition joint between the first and second sections of the one of the plurality of cross-members.
 9. The method of claim 8 wherein welding a first end of a first side plate to a bottom surface of the top plate comprises welding the first end of the first side plate to the bottom surface of the top plate at a location between a first end of the top plate and a center of the top plate; and wherein welding a first end of the second side plate to the bottom surface of the top plate comprises welding the first end of the second side plate to the bottom surface of the top plate at a location between a second end of the top plate and the center of the top plate.
 10. The method of claim 8 wherein welding a second end of a first side plate to a top surface of the bottom plate comprises welding the second end of the first side plate to the top surface of the bottom plate at a location between a first end of the bottom plate and a center of the bottom plate; and wherein welding a second end of the second side plate to the top surface of the top plate comprises welding the second end of the second side plate to the bottom surface of the bottom plate at a location between a second end of the bottom plate and the center of the bottom plate.
 11. The method of claim 8 further comprising forming at least one central opening having a perimeter surrounded by intersecting side rails and cross-members.
 12. The method of claim 9 wherein each corner of each central opening had a curve matching an inner perimeter of a respective gusset portion.
 13. The method of claim 8 wherein forming each side rail comprises surrounding a hollow cavity with the top plate, bottom plate, first side plate, and second side plate; and wherein forming each cross-member comprises surrounding a hollow cavity with the top plate, bottom plate, first side plate, and second side plate.
 14. The method of claim 8 wherein intersecting each cross-member with the plurality of side rails at a plurality of intersection points comprises orienting each cross-member perpendicular to each side rail.
 15. The method of claim 8 wherein forming each side rail and each cross-member comprises orienting the first and second side plates perpendicular to the top and bottom plates.
 16. A chassis frame of an agricultural sprayer comprising: a main support section configured to support at least one of an operator cab and a product tank; an engine support section configured to support an engine, the main support section and the engine support section are collectively defined by: two side rails oriented parallel to each other, each side rail comprising: a top plate; a bottom plate spaced apart from and oriented parallel to the top plate; an inner wall plate extending from a bottom surface of the top plate to the top surface of the bottom plate; and an outer wall plate extending from the bottom surface top plate to the top surface of the bottom plate; a plurality of cross-members oriented perpendicular to the side rails and extending therebetween, each cross-member comprising; a top plate; a bottom plate spaced apart from and oriented parallel to the top plate; a front wall plate extending from a bottom surface of the top plate to the top surface of the bottom plate; and a rear wall plate extending from the bottom surface of the top plate to the top surface of the bottom plate; a top wall extending over the top plate of at least one of the plurality of cross-members and over the top plate of at least one of the plurality of side rails; and wherein: each cross-member extends from a respective side rail at a respective one of a plurality of intersection points; a plurality of gusset portions is formed between the top plate of the side rails and the top plate of the cross-members at each intersection point; the top plate of one of the plurality of cross-members includes a first section having multiple angled edges defining a pocket therein and a second section having multiple angled edges defining a protrusion; and the protrusion is receivable in the pocket so as to define a transition joint between the first and second sections of the one of the plurality of cross-members.
 17. The chassis frame of claim 16 wherein a portion of the top plate of each side rail adjacent an inner edge of the top plate extends beyond the inner wall plate of the side rail.
 18. The chassis frame of claim 16 wherein a portion of the top plate of each cross-member adjacent a front edge of the top plate extends beyond the front wall plate of the cross-member.
 19. The chassis frame of claim 16 wherein a portion of the top plate of each cross-member adjacent a rear edge of the top plate extends beyond the rear wall plate of the cross-member.
 20. The chassis frame of claim 16 further comprising at least one central opening having a perimeter surrounded by intersecting side rails and cross-members. 